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Pyroprocessing II S1-Clinker Cooler Equipment Overview: Basic Functions Overview of Basic Types/designs

The document discusses clinker coolers, which are used to cool hot clinker from cement kilns. It provides an overview of the basic functions of clinker coolers, including cooling clinker, quenching it to prevent degradation, recuperating heat, and transporting and crushing clinker. It then describes the main types of clinker coolers: rotary coolers, satellite or planetary coolers, G-coolers, and grate coolers. Grate coolers are noted as the most popular type due to their good heat recovery, better cooling control, and ability to recuperate excess heat for other processes.

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196 views15 pages

Pyroprocessing II S1-Clinker Cooler Equipment Overview: Basic Functions Overview of Basic Types/designs

The document discusses clinker coolers, which are used to cool hot clinker from cement kilns. It provides an overview of the basic functions of clinker coolers, including cooling clinker, quenching it to prevent degradation, recuperating heat, and transporting and crushing clinker. It then describes the main types of clinker coolers: rotary coolers, satellite or planetary coolers, G-coolers, and grate coolers. Grate coolers are noted as the most popular type due to their good heat recovery, better cooling control, and ability to recuperate excess heat for other processes.

Uploaded by

LuisFernández
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Pyroprocessing II

S1-Clinker Cooler
Equipment Overview
Basic Functions
Overview of basic types/designs

Contributors:
Michel Beaupr (03)
Sam Fujimoto (09)

Section 1 - Objectives

Understand the basic functions


(purposes) of the clinker grate
cooler
Become more familiar with the
different types of clinker cooler
technologies used and their
limitations.

Content

Functions of a cooler
Overview of cooler types
Rotary

cooler
Satellite/Planetary cooler
G-cooler
Grate Cooler

Functions of a clinker cooler

Clinker cooling

Quenching

Rapidly freeze clinker alites, prevent degradation to


belite

Heat recuperation (at a steady temperature)

Modern goal = 65C - 70C + ambient

25-40% of energy budget needed to produce clinker


comes from the cooler. Impact on performance is
large.
Also minimizing heat loss to vent system protects
equipment.

Transportation & Crushing

Precrushing improves finish grind output the more


uniform the better.

Related functions and auxiliaries

Provide drying heat for the coal mill,


raw mill, AF (future), perhaps power
generation.
Heat exchanger and dust collection
Amongst

the biggest source of


particulates for a cement plant
Main dust source in kiln building
(housekeeping)

Categories of cooler types

Rotary
Satellite (planetary)
G-cooler
Grate cooler (see section 2a)
Reciprocating
Airbeam
Walking

floor type

Rotary cooler

kiln

cooler
Simplest
Good Heat Recovery Poor Cooling
Efficiency
Draft/cooling control by kiln ID fan
Tend to overdraft kiln lower secondary
air temperatures
Ideal in zones where access to parts or
skilled mtce. support is lacking
Or kiln output is very small

Satellite (Planetary) Cooler

Simple
Good heat
recovery Poor
cooling efficiency

But better than


single rotary cooler

High maintenance
Draft/cooling
controlled by kiln
ID fan

pulls at flame

Maintenance Issues with Satellite


Coolers
Need lifters
to improve
heat
exchange

metallic

refractory

Frequent
refractory
failures at ports
and elbows

G-cooler

By Claudius Peters
Promoted to finish cooling after main unit
Very high wear problems

G-cooler Inside

Not a popular alternative. Wear


problems and extra equipment adds
to maintenance costs.

Grate Cooler

Most popular
Best heat recovery
Better control

forced draft cooling and in most


cases independent hood draft control

Numerous variations of design

Other advantages of a Grate Cooler

Good quenching
High production capacity
Excess heat can be used for other
purposes:

coal mill
raw mill

Independent control loops that stabilize


kiln operation
Build-in crushing and sizing of clinker

Disadvantages

High power consumption


Require vent air systems with dust
collectors
Many moving parts (many things to
fail)
Difficult to operate with fine clinker

Challenges with (Grate) Coolers

A poorly operated cooler worsens kiln


stability and heat consumption

A poorly operated kiln abuses the cooler

About 1/3 of required energy comes from the


cooler
Coolers are a large source of incident kiln stops
Grate coolers have a large number of parts
Maintenance expenses are large

Stable kiln is important, but also need a


robust cooler
Good operations AND maintenance is very
important.

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